Apparatus for molding plastics



June 15, 1948.. I, p, 5 MATTIA V/ALPPARATUS FOR MOLDING PLASTICS Filed Apl il 6, 1944 m 1 1. 71/ F 4 0 2 8 9 2 I I 2 2 v @INVENTORI 5 A I m w Patented June 15, 1948 UNITED STATES PATENT OFFICE 5. Claims. 1 This invention relates to improvements in apparatus for molding plastics including thermosettlng and true thermoplastic"materials.

ne-object of the invention is to provide an improvement in apparatus for molding large charges-of plastics whereby premature setting of 'thermosetting materials is avoided, and burning 'of 'true'thermoplastics is avoided;

More specifically, it is arr-object of the invention 'to'provide apparatus for the dieor'extrusion moldingo'f relatively large charges of plastics, which may be one to one hundred pounds or even-larger. For this purpose the plastic may be fed to the heating cylinderby a series of sma'll strokes of one or more pistons or by a single-long stroke of a piston. Theaccumulated largecharge of plastic-must then be heated to become substantially uni-formlyfused-for a rapid ejection into a die. In practice, it is difficult if not impossible to heat a large charge without heating. some parts of the charge for too long a time "or producing an excessive temperature therein; Such over-heating results in premature setting of thermosetting materialsor burning of truethermoplastics; This has posed atprob lem which :hasn-ot; beenrsolved heretofore, to my knowledge. With thermosetting -materials,-the "die 'is 'heated" and impartsconsiderable heat to the: heating cylinder by contact therewith,thus aggravating the problem. It has been. roposed to=- overcome this diffi-culty bywater GOOIi-Ilg'thfl injection nozzle of the heatin cylinder,- but-this has been found to be unsatisfactory.

It is, therefore, an object of the invention to avoid these difiiculties and *to :provide apparatus for the melding oflarge charges. of plastics;

The utility of the invention is best exemplified in the treatment of thermosetting materials, in which an increase in the temperature or in the time of heating may cause premature setting. Hence-evenif only verysmallquantities ofsuch materials suffered premature setting they would become so hard that they could not be ejected,

:not-couldthey be eliminated by further heating.

They would clog. theapparatus which WOllld'hfifl/B to be shut down and-cleaned. Iiperceived, therefore, that it was essential that virtually every particle of such gplastic. used in a. cycle beejected in :thatparticular cycle so that it maynot be heated too long before injection into the mold.

The difiiculty mentioned was increased in attempting .tomold large articles. of thermosetting materials'because the following factors were in.- volved: First,v the-largepl-astic; charge-'hadito .be heated. relatively-slowly to, zassurezuniformvtusiQn 2 Without overheating or premature setting; according to the best practise such heating is done in a chamber having a flow dividing heating member or flow constricting means relatively close to the outlet-or injection port for the mold.

Second, the feedof plastic from the heating v chamber to the injectionport isd'ependent upon the resistance of unfused as well as fused plastic and is therefore rather high and Varies with different plastics; therefore the flow is inherently limited to relatively low speeds for good performance without undue wear on the 'machine. Third, the charge should be fed to a reservoir or storage chamber'an'd thence to the mold at relatively high velocity for rapid, economi-calmolding and uniform setting of theplastic indifferent parts of .the mold (by further heating for thermosettingplastics and: by chilling for true thermoplastics). Fourth, in the cycle involved, the fused plastic must be ejected into the mold from the storage chamber without leaving any residue or adherent plastic for another cycle and consequent over-heating; this must be accomplished without using val-ves'or other moving parts which may require that they in turn be cleaned of residue or adherent plastic.

It is therefore an object of the invention to furnish an improvement in the art Which, on the basis of the factors involved, shall solve the difficulties mentioned and assure ejection of the residue plastic after ithas been heated for a "certain time or within a given cycle.

Another object of the invention is to furnish van improvement in the art whereby one flow path for-stored plastic merges into another whereby the relatively fresh plastic in the latter cleans a feeding instrumentality of the former of residue plastic for ejecting such residue into a mold.

More specifically, the invention provides for the. feeding-of the stored plastic through them- .jection port, and the disposition adjacent to the latter of the residue of such feed, followed by a plastic flow from the fusingchamber direct to the injection port to pick up and eject the residue for a complete ejection of the stored'plastic and of'theadvance highly heated plastic at the fusing chamber.

Another object of the invention isto provide improvement in the art whereby the reservoir chamber, or at least the-piston thereof cooperates with adjoining parts'of the apparatus to furnish relatively low resistance tapered passage to the outlet orifice for the follow-up flow of plastic from the heating cylinder; and preferably there .may be avalve for'said orificesufficiently enlarged or formed like a piston so that its working face may cooperate with that of the reservoir piston to provide a conoidal passage for the plastic to said orifice; the method involved thus providing for a change in the flow contour upon expulsion of the plastic from the reservoir so that an alined flow from the high resistance heating cylinder can occur through a convergent region forming an entrance to the orifice.

Other objects and advantages of the invention will become apparent as the specification proceeds.

With the aforesaid objects in view, the invention comprises the novel features, combinations and arrangements of parts hereinafter described in their preferred embodiments, pointed out in the subjoined claims, and. illustrated in the annexed drawing, wherein like parts are designated by the same reference characters throughout the several views.

In the drawing:

Figure 1 is a. diagrammatic, fragmentary horizontal sectional view showing a device embodying the invention and illustrating the first step of the cycle according to my novel process.

Fig. 2 is a similar view showing a substantial part of the plastic charge transferred to the reservoir or second location from the heating chamber, completing the operation begun in Fig. 1.

Fig. 3 is a similar view with the die or mold in position and the plastic ejected into the die by the advanced piston at the second location.

Fig. 4 is a similar view with the primary piston advanced from its position of Figs. 2 and 3 to eject an additional charge of plastic to the die.

Fig. 5 is a similar view with the ejection nozzle closed as in Figs. 1 and 2 and showing the primary piston fully retracted for loading another charge to begin another cycle.

Fig. 6 is an enlarged sectional view taken on line 66 of Fig. 3.

Fig, 7 is a schematic View showing an apparatus embodying the invention with particular reference to the actuator means for the various moving parts.

The advantages of the invention as here outlined are best realized when all of its features and instrumentalities are combined, but, useful embodiments may be produced involving less than the whole.

It will be obvious to those skilled in the art to which the invention appertains, that the same may be incorporated in several different constructions. The accompanying drawing, therefore, is submitted merely as showing a preferred exemplification of the invention.

Referring in detail to the drawing, ll] denotes an apparatus embodying the invention and illustrating my novel methods of making large plastic articles by molding in a die or by extrusion through a die, with the use of large charges of plastic, weighing one to one hundred pounds or more, without causing premature setting of thermosetting materials or burning of true thermoplastics. The apparatus l0 may include a casing having a first cylinder ll having a lateral outlet nozzle or orifice at l2 located intermediate of the ends of the cylinder ll. Disposed in the latter at opposite sides of the nozzle are pistons l3 and M which may be independently reciprocable, except perhaps as in Fig. 5 hereinafter described, in which piston l4 may directly push piston I3 rightward, and in Fig. 4 in which piston l3 may move piston M leftward by exerting pressure on the plastic. Hence the cylinder H may be regarded as comprising individual cylinders i311. and [4a for the respective pistons. The opposed working faces of these pistons are adapted to accurately contact each other along a plane l5 which may be at right angles to the pistons. Formed in the working face portions of the pistons are tapered recesses l6, see Fig. 6, which conjointly provide a generally conoidal central orifice or entrance adapted to aline with the nozzle 12 as in Figs. 3 and 4; this conoidal entrance is centrally split along the plane at l5, and at its small end I! is substantially equal in diameter with the orifice of the nozzle l2. Intersecting the cylinder II at an angle is a second cylinder l8 whose internal diameter may be equal to that of the large end of the said conoidal entrance. In this cylinder is a reciprocating piston l9 operative independently of the others but capable of causing retraction of piston l3 as in Figs. 1 and 2 by exerting pressure on the plastic. A portion of the cylinder l8 adjacent to the cylinder 1 I affords a heating chamber 20 for melting or fusing the plastic. Heat may be supplied to this chamber in any suitable manner as by an external annular heating element 2|, and by an internally heated element 22. The latter may be constructed and arranged as disclosed in my Patent No. 2,271,063, issued January 27, 1942, which is incorporated herein by reference. Thus the element 22 is centrally located and is connected to the cylinder l8 by a series of radial webs, its function being to divide and thin down the flow for a rapid and uniform heating of the plastic as it passes through the heating chamber 20. Incidentally, this element 22 causes considerable resistance to the flow of the plastic, and. this resistence is a serious factor where a large charge of plastic must be ejected with considerable rapidity into a die. A similar heating element may be provided for the reservoir l3a, but the same may be heated solely by the plastic, and may be insulated if necessary. Finally, it may be noted as to the apparatus ID that while the piston I9 is a primary and the piston l3 a secondary or transfer or reservoir piston, the piston I4 is primarily a valve for opening the nozzle l2 for communication with the die 23 as in Figs. 3 and 4 and for closing said nozzle as in Figs. 1, 2 and 5. In that respect any suitable thin plate valve might be used, with the piston l3 and its recess I6 cooperating with an adjoining wall or part of the apparatus to afford a suitable entrance to the nozzle l2, but the best results are obtained, and in the simplest manner with the apparatus disclosed.

The process embodying the invention will now be disclosed. After the cylinder 18 has been loaded with the relatively large charge of plastic, supplied thereto in any feasible manner, the cycle may be said to start at Fig. l. The primary piston l9 advances with a powerful pressure, while the valve piston I4 is in closing position, and the secondary piston I3 retracts by operation of an actuator or by the pressure of the plastic itself. In Fig. 1 this retraction has started, and it continues until substantially all of the large charge has been received in the transfer chamber l3a as in Fig. 2. As the plastic flows through the heating chamber 20, it is progressively fused, and in the transfer chamber l3a little or no heat may be supplied, so that the temperature in the latter may be somewhat less than at the heating chamber 20. This avoids any premature setting or burning of plastic. It may be added that the conoidal face at I6 assists in imparting axial pressure to the secondary piston, which is useful because of the high viscosity of the plastic. *No 'entrapment: of air occurs, an'd'vany air particles in the plastic flow backward and out past the piston. IB becauSe of. the high' resistance interposed. by the element 22 as previously 'mentionedi I-lence' themo'lded 'article'wvill be free of blemishes-'causeduxby-entrappedsair.

'According to the next stepofithe process, the primary piston l-9 has temporarily'comezto rest: as in1Fig'. '3an'dthe secondary piston 1'3 advances. This. immediately causes: retractioniof. the piston valve; l4 either as a-result ot-anincreased pressure onithe'plastic'or as a resultof' aidiminished resistanoe-ioff the piston valve. Whi1e-thet:primary;pistonwiss'held rigidly stationary; the' secondarypisr .ton :now expels all the plastic in '..the transfer chamber l3a through the nozzle 12 into: the" die 23:.which'has moved into. communication with 'the nozzle: Such expulsion of a large quantity of plastic may occur withgreat rapidity because.- the resistance to flow is substantially less than. inithe cylinder I 8. During this: expulsion the recesses .l:65"form* the conoidal entrance in truelalinement with the'nozzle' l2. 1

According to the next step, and' 'while the pistons |-3,- M are heldwrigidythe-primary piston'ztfl advances to eject anadditional or follow-up charge or quantity' of plastic into the die'to complete" the article. -If the total weight'of 'the-"articlebe about 5 to 100 pounds or more, .thisfinal *ejection may be about 1 or 2pounds or'more. This final ejection is an important featureofithe. process and isanot merely a folloW-updnjectionto take care of shrinkage. Its purpose is to gather up or entrain th'e residue of the'ejection from the reservoir' or transfer chamber .l'3a'. Such residue may be adherent to the-piston lii and. may-remain: in the recesses l6. It is susceptible to"burning orvpremature setting sinceit hasrem'ained': for

some time in heated conditionintheftransferchamben'representingthe very first part of the charge received by that chamber. Accordingly, the final eject-ionby the'piston lflserves to eject that residue and serves to clean the-recesses. l6.

Also this final ejection by pistons!!! represents plastic whichhas been heatedwhile the charge of the transfer chamber was being ejected, and hencerit'is desirable to expeliitfiwithout further'de lay into the die.

='Upon completion of the step indicated in Fig.4,

the pistons I3, I4 are moved rightward, so that. the "piston 44 closes the nozzle $2.

This may be effectedin a simple manner by releasing'pistonffl :atieastin part-and giving the .valve :pi'stona in readiness for the succeeding step of Fig. 1 to produce another article. The die 23 may represent -a mold or extrusion'die. The temperatures usdmayvarywith the plastic thus the temperatures in the heating chamber 20 may be less for thermosetting than for true thermoplastics. With the latter, the die 23 may be Water cooled, and with the former it may be heated.

The actuator means for the performance of the foregoing process and for operating the apparatus may be quite obvious, and may be mechanical or hydraulic with timing or electrical stop and start controls responsive to the pistons or to other controlling devices. However, in order to show one possible arrangement, reference is now briefly had to the simplified schematic view of Fig. 7. Power cylinders are provided for 6 the pistons andi forthe dle; thesevbeingtprefenably identified by their pistons 'A',:. B, G and-.D for: the respectivezmembersilfl, I 3,:I42Land Z3; In the case of the die,1. its .-piston;D may cause opening: and closing or the die-.- as wellzas' movement Ofi thezdie toward rand away from thenozzle- I2; Arhi'gh pressure reservoir 25 may be provided'and'ca pressurer'r'eservoir -26- "having asipressure less. than that of the'reservoir'fi. Differentwen ds of the cylinder of piston-"Amayibe connectedrespectively; to reset.- voirsi25 andfizfi as by valves a andaal. Di-fierent ends'ofi the cylinder for piston Brmaybeconnected respectively to reservoirs 2 5: andr26; as byvalves b and bl; Different sends .o-f'the cylinder for the piston 0 maybe connected respectively to -the reservoirs 25, 2'3 as by valves 0 and cl. aAnd finally; different ends of: the cylinder for" the-,pis-

tonaD: may be connected tothe respective: reser-- voirs-ZS; was by-valvcs 'd and d I. All of-. the

-valves a,-b, candid may bermechanically or electrio-ally;controlled: for timing :and? otheraction-z as by any suitable device 21'; andsimilarlyall the valves al, bl, b2, cl and all may be controlledrby any device-28.- The devicesZI, 28- maybe interconnected or coordinated mechanically-or electrically. asv indicated by a connection 29, toiassure proper timing,.and. one ofthe dcvices-2-1 or-ZB may-represent a master control. Such control maybe coordinatedwith or supplemented by suitable well known devices including contact switches at thepistons or othermoving parts to assure precise. operation, and may in fact controlor operatein. lieu of timing devices, so that thetravel of. the, plastic itself may .constitutethe dominant timing factor.

In operation, .for. Fig. 1,. valves wandal maybe fully open so thatthepiston A advances,- vvith pressure exiting from. the front of piston. A. to reservoir 26. During this time valves 0,. cl'and b are -closed,..but.. valves bl. andbz are openat least inpart so that valvepiston I4. is heldrigid while piston I3 is retracted bypressure of the plastic against. which it. may offer some resistance. f Since the die His-stationary. valves. d and dl; are closed.

Next the valvesa, a! are closed, so that the piston I9 is stationary. Simultancou'sly,. the valve 1) isopened while valve 222 is.closed causing ad'- vance of the-piston 13 to the position. of-Fig."-3.

Since thezpiston I4 is retracted from the. posi!. -tion in'Figc 2 by the force of piston l3, the valve cl is opened while valve 0 may be moved-to a restricted.bleedingposition-soas to cut off .the

pressure from. reservoir- 25 while permitting-such bleeding from the rear of its, piston. C. as. to. cause the piston Hi to offer a resistancewhile.receding.

-Instead of the bleedinguat valve 0, 'an additional .pipe. line may be employed to reservoir. 2.6 with -a-valve likezthat at b2, toeause operation-as in the case of the-"piston B. With the initiation of the 'aboveoperations, valves d and" d hare opened =soitha-t: the die- 23 moves. into operative relation .andis constantly pressed againstthanozzle n.

Thentthe valves b and-bland c andcl are closed so that the pistons l3, M are rigidly stationary, and valves a and al opened to cause the piston I9 to advance from its position in Fig. 3 to that in Fig. 4.

Finally valves 0, cl are opened to cause the piston C to advance under pressure from 25 with liquid in advance of the piston bleeding into 26 until piston I4 reaches the position as in Fig. 5. Simultaneously, valves bl and b2 open so that the piston l3 may recede under the force of piston l4, as described for the position of Fig. 1. Simultaneously valve a is closed and moved to a pressure bleeding position, while valve al is opened so that pressure from 26 causes-retraction of the piston A and hence of piston I!) to the filling position. At the same time valve (1 closes but moves to bleeding position, with valve dl remaining open so that pressure from 26 will move the die to open or inoperative position away from nozzle l2. Obviously in the case of pistons A and D, the higher pressure in reservoir 25 may be used to cause retraction by suitably switching the connections with multi-way valves between their cylinders and the reservoirs 25, 26, but the simplified showing herein is sufficient to illustrate the operation involved, with the use of valves such as a, c and d movable to open and closed positions and to an intermediate position in which they may bleed liquid to some other reservoir or to a drain pipe. If desired, the reservoirs may be interconnected to circulate the liquid, as

with the aid of suitable pumps, to avoid any waste, but this being conventional practice, is not shown herein.

I claim:

1. Molding apparatus for plastics including a first cylinder having an outlet orifice in a side wall thereof intermediate of the ends of the cylinder, a second cylinder communicating with the first cylinder at an angle thereto and being in approximate alinement with the outlet orifice, pistons in the first cylinder at opposite sides of the outlet orifice and having Working faces confronting each other, said pistons each having a recess at its working face of the shape of a portion of a generally conoidal surface, the recesses of the pistons registering with each other when the pistons are in contact with each other to provide a passage converging from the second cylinder to the outlet orifice, and a piston in the second cylinder.

2. Molding apparatus according to claim 1 wherein means is provided for advancing one piston in the first cylinder to move past and to thus close the orifice and for thereafter advancing the piston. in the second cylinder, with the other piston in the first cylinder retracting so as to afiord a reservoir for receiving plastic, and for thereafter advancing the said other piston in the first cylinder with its opposed piston retracting to uncover the orifice for ejecting the plastic, with the pistons in the first cylinder being finally positioned to produce said convergent passage alined with the orifice, and for thereafter causing an advance of the piston in the second cylinder for a follow-up charge of plastic through the alined convergent passage.

3. Molding apparatus including a first cylinder having an outlet orifice in a side wall thereof intermediate of the ends of the cylinder, a second cylinder communicating with the first cylinder at an angle thereto and in approximate aline- 60 ment with the outlet orifice, pistons in the first cylinder at opposite sides of the outlet orifice and having working faces confronting each other termediate of the ends of the cylinder, a second cylinder communicating with the first cylinder at an angle thereto and in approximate alinement with the outlet orifice, pistons in the first cylinder at opposite sides of the outlet orifice and having working faces confronting each other and being at different obtuse angles to the axis of the first cylinder, said working faces cooperating with each other to form an entrance convergent from the second cylinder to the outlet orifice, and a piston in the second cylinder, and means for advancing one piston on the first cylinder to move past and to thus close the orifice and for thereafter advancing the piston in the second cylinder with the other piston in the first cylinder retracting so as to afford a reservoir for receiving plastic, and for thereafter advancing the said other piston in the first cylinder with its opposed piston retracting to uncover the orifice for ejecting the plastic, with the pistons in the first cylinder being finally positioned to produce said convergent passage alined with the orifice, and for thereafter causing an advance of the piston in the second cylinder for a follow-up charge of plastic through the alined convergent passage.

5. Molding apparatus according to claim 4 wherein the orifice closing piston and its companion piston in the first cylinder have end abutment with each other so that the companion piston moves the orifice closing piston to a retracted position in which the orifice is opened coincident with the formation of the alined convergent passage.

PETER DE MATTIA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,111,857 Jeffery Mar. 22, 1938 2,137,764 Wagner Nov. 22, 1938 2,156,396 Macklin May 2, 1939 2,202,140 Burroughs May 28, 1940 2,207,426 Bailey July 9, 1940 2,252,107 Weida Aug. 12, 1941 2,268,026 Ernst et al Dec. 30, 1941 2,332,679 Tucker Oct. 26, 1943 2,349,176 Kopitke May 16, 1944 2,359,840 Goessling Oct. 10, 1944 FOREIGN PATENTS Number Country Date 501,277 Great Britain Feb. 21, 1939 

